CN1476375A - 连接塑料薄片材料的方法 - Google Patents

连接塑料薄片材料的方法 Download PDF

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CN1476375A
CN1476375A CNA018194427A CN01819442A CN1476375A CN 1476375 A CN1476375 A CN 1476375A CN A018194427 A CNA018194427 A CN A018194427A CN 01819442 A CN01819442 A CN 01819442A CN 1476375 A CN1476375 A CN 1476375A
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戈登·库克
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Abstract

一种连接薄塑料薄膜或薄片材料的方法，用于形成密封的压力容器，尤其是用于医药业的容器，例如血袋或尿袋。实践显示，由于在靠近由射频焊接连接薄片材料的焊点附近的区域的疲劳应力，普通使用的囊材料的失效工作寿命的分布很宽，该射频焊接是普通的现有方法。在本发明中，使用塑料注射模制方法是可更精确控制和可重复的方法，塑料注射模制方法在要连接材料的熔点之下工作，这样，避免了由于射频焊接引起的材料退化而产生的早期疲劳。

Description

连接塑料薄片材料的方法
发明领域
本发明涉及一种连接薄塑料薄膜或薄片材料的方法，以便形成密封的压力容器，尤其是用于医药业的容器，例如血袋或尿袋。
背景技术
用于构成密封压力容器的普通方法是利用射频(RF)焊接将塑料薄片材料粘接在一起以形成容器。在该方法中，高频电流通过作为绝缘体保持在一对射频电极之间的塑料材料。由该处理产生的热足以使要粘接的材料熔化，并使邻接的塑料薄片之间进行熔合。利用机械压机向熔合区域施压，以便完成焊接。
采用射频焊接的问题是粘接质量不可靠，尤其是在焊点周围的热影响区域中的材料强度不可靠。
在很多医药用途中，这并不是很有效，因为在预定的使用寿命中，所形成的容器只能用一次。
不过，在其它情况下，在连续使用较长时间时，所形成的容器的完整性很重要。
对于广泛用于医疗领域以增强人体中的血液循环的A-V ImpulseSystemTM装置的可膨胀囊(bladder)，这尤其重要。
当该装置抵靠人的肢体例如足底弓时，通过以预定循环频率将增压空气配送给囊而操作该装置。病人的治疗可以以该循环率持续多天，在此期间，重要的是形成囊或包围区域的塑料表层之间的焊接必须不能失效。
实验显示，由于由射频焊接产生的焊点的附近区域的疲劳应力，通常使用的囊材料有较宽的失效工作寿命分布很宽。
因此，可以考虑通过简单增加囊材料的厚度来适当克服该问题，这在实践中产生很多缺点。例如，材料的厚度增加将使它的硬度增大，因此，在该囊和它所用于的人体部分之间的柔顺性降低，另外，该囊更难膨胀，从而导致脉冲能量损失。而且，通过以该方式增加囊的工作寿命将鼓励在病人之间的重新使用，这可能导致污染物的交叉感染。
发明内容
本发明的目的是提供一种利用塑料注射模制方法而以可更精确控制和可重复的方式连接塑料薄片材料的方法，该方法在低于要连接的材料的熔点的情况下工作，因此避免了由于由现有技术的射频焊接方法在连接区域中引起的材料退化而产生的早期失效。
根据本发明的一个方面，提供了一种连接两个塑料薄片材料的方法，该方法包括：将薄片的外周边缘部分以交叠关系保持在一起；以及环绕该薄片的外周边缘模制弹性体材料小珠，以便粘接该薄片材料以形成密封接头。
优选是，该小珠通过在模腔中注射模制而形成，其中进行注射模制的温度低于薄片的塑料材料的熔点。这样，可以避免基体塑料材料象射频焊接那样产生基体塑料材料退化。
根据本发明的还一方面，提供了一种压力容器，它包括沿密封接头连接在一起的第一和第二外部塑料表层，该密封接头由模制在表层的外周边缘上的弹性体材料小珠形成，并形成密封接头线。
下面将参考附图接收本发明的其它特征和优点。
附图描述
在附图中：
图1(a)、(b)和(c)分别表示了根据现有技术用于在塑料薄片材料之间形成焊接接头，以便形成可膨胀囊的射频焊接方法的平面图、侧视图以及沿图1(a)中的线A-A的详细剖视图；
图2(a)、(b)和(c)分别表示了根据本发明用于将两个塑料薄片材料连接在一起以形成可膨胀囊的方法的平面图、沿图2(a)的线A-A的剖视图以及侧视图；
图3(a)和3(b)表示了图2所示的本发明实施例的属性；
图4表示了根据本发明形成覆盖模制封闭小珠的焊接方法的变化形式；
图5(a)和(b)分别表示了现有技术的射频焊接接头以及根据本发明形成的接头，表示了本发明优于现有技术的优点；以及
图6表示了利用本发明的方法构成可膨胀囊或其它压力容器的相应制造方法。
实施发明的最佳方式
参考图1，图中表示了利用射频焊接形成A-V Impulse SystemTM的可膨胀囊的普通方法。
图1中所示的囊包括两个卵形柔性塑料薄片1和2，这两个塑料薄片沿它们的交叠外边缘部分通过射频焊接而焊接在一起。该囊有用于增压空气的进口管3，该进口管3与形成于表层2上的模制进口凸台4相连。
在本实例中采用的囊表层的厚度为0.25mm。囊1和2的边缘部分保持交叠关系，如图所示，射频焊接通过将电极6、6’靠拢而用于离表层1和2的外周边缘一定距离处的区域5中，以便在7处形成减小厚度的横截面，通常为初始厚度的50％-70％。
焊接的结果是在两个材料的8处，直接靠近焊接区域的材料收缩成颈状，并在表层1和2之间形成熔融聚合物的挤出小珠，如图所示。
用于形成可膨胀囊的本发明新方法与射频焊接方法完全不同，如图2至6所示。
在图2中，可膨胀囊也成卵形，并由两个柔性塑料薄片或表层10和11构成。在该方法中，与射频焊接方法相比，表层10和11只是在它们的外周边缘通过弹性体材料的包覆模制小珠12进行连接，优选是，该弹性体材料选择为在可接受的较低处理温度下粘接到表层材料10、11上，该较低处理温度不会由于早期疲劳和故障而导致囊材料变形、损坏或其它性能退化。
用于囊表层10和11以及封闭小珠12的合适材料组合是基于聚丙烯的材料。因此，囊的表层10和11可以是聚烯烃膜，而用于形成粘接的包覆模制小珠12是选择为对聚烯烃有最佳化学亲和力的热塑性弹性体。
为了增加膜的强度，以便使病人舒适，可膨胀囊的外表面可以层压到无纺材料，例如多孔聚酯。
如前所述，将塑料材料粘接在一起的新方法有很多优于普通射频焊接的优点。
如图2所示，在接头区域上和超过接头区域的部分，囊的表层10和11的厚度保持基本恒定，并且产品和产品之间也保持恒定。因此，与射频焊接方法形成的接头相比，不会导致强度减小或疲劳寿命减小，而该射频焊接方法如图1所示，必然导致表层材料在处于熔融状态和压力下时变形，从而导致横截面厚度减小。
而且，在接头的横截面中没有突然的台阶变化，该台阶变化可能易于产生异常应力。
图2中所示的接头在低于囊表层10和11的材料的熔点的温度下生成，这样，对基体材料的固有特性基本无影响。相反，射频焊接中，材料升高到熔点温度或更高，表层材料的化学结构例如可能通过除去包含在聚合物中的增塑油而改变，从而导致变脆和早期疲劳，如前所述。
图2中所示的接头的优点是，由于包覆模制小珠12的型面的认真设计，表层10和11在负载作用下的应力通过锥形的应变释放部分逐渐传入小珠12，而没有突然的剖面变化。
下面进一步介绍本发明的方法的优点，包覆模制小珠12设计成在膨胀过程中能使囊最大膨胀，并使囊表层10和11最大分离。因此，包覆模制小珠12可以形成于接头处，从而使囊在膨胀时的负载作为撕开力施加到小珠12上，以便通过铰接作用而在小珠12自身内撕开，如图3(a)和3(b)所示，该图3(a)和3(b)分别表示了当囊膨胀时(见图3b)小珠12怎样适应该拉伸。
因此，当用于形成包覆模制小珠12的材料具有相当弹性时，由于快速膨胀而引起的应力和冲击的一部分通过接头自身的有限伸展而吸收。
包覆模制小珠12的横截面适于使固有强度和粘接强度最大，同时不足以影响病人可接受的柔顺性，例如当与脚配合时。通过将小珠12的横截面改变成使内部的封闭单元泡沫塑料结构13装于同样密度的表层表面14内部，从而更有利于提高对病人的柔顺性，如图4所示。
图2中所示的接头提供了较长的泄漏通路，如图5所示，从而防止装于该囊内的流体泄漏到大气或周围环境中。
而在普通的射频焊接中，泄漏通路可以直接通过靠近焊点处的较薄基体材料厚度部分14、15，如图5(a)所示，而在本发明的包覆模制设计中，泄漏通路如图5(b)所示，通过两个啮合表面16、17和一个基本相同的基体材料厚度。
本发明的包覆模制接头的一个优点是，由于疲劳失效引起的泄漏可能性非常小，同时与粘聚结合相反，不会产生由于粘合结合在使用时层离而引起泄漏，因为由于小珠的设计而不会产生这样的故障。
本发明的包覆模制的还一优点是接头的外周边缘密封，这样，模切分开边缘的烦恼或不便都可以避免，当有分开边缘时，灰尘和污染物可以停留在分离层之间。
在图6中表示了根据本发明采用包覆模制小珠方法制造可膨胀囊或其它压力容器的典型制造方法。
要形成的容器的表层壁18、19装入塑料注射模制工具20中，该工具20有模腔21，适于形成包覆模制小珠。
模制工具20的尺寸设置成能够在点22处施加足够压力，以防止高压熔融热塑性弹性体流出该工具20，因此，当工具20在所示位置夹住关闭，并流入表层18、19上和之间。
可缩回芯销23、24以合适间距布置在模腔21内，以便在包覆模制处理的第一阶段保持表层18和19的未支承端部。
当工具20关闭和可缩回芯销23、24向内布置在充分向前的位置时，熔融弹性体通过浇口25注入。在注射循环的预定阶段，当弹性体开始凝固时，可缩回芯销23、24退出，并继续注射处理，直到最终充满由销23、24留下的空腔26。
尽管参考A-V Implus SystemTM的可膨胀囊的形成介绍了本发明，但是本领域技术人员应当知道，本发明可以广泛用于其它压力容器的结构，并不需要是医药领域，实际上可以是需要使塑料薄片层离彼此粘附以形成密封接头的任意情况。

Claims (7)

1.一种连接两个塑料薄片材料的方法，包括：将薄片的外周边缘部分以交叠关系保持在一起；以及环绕该薄片的外周边缘模制弹性体材料小珠，以便粘接该薄片材料以形成密封接头。
2.根据权利要求1所述的方法，其中：该小珠通过在模腔中注射模制而形成，其中进行注射模制的温度低于薄片的塑料材料的熔点。
3.根据权利要求2所述的方法，其中：薄片的外周边缘通过可缩回的销在模腔中保持在一起。
4.根据权利要求3所述的方法，其中：在形成小珠后将可缩回销退出，并继续注射模制处理，直到以熔融弹性体材料充满以前由该可缩回销占据的空间。
5.根据前述任意一个权利要求所述的方法，其中：该塑料材料是聚烯烃膜材料，而注射材料选择为与该聚烯烃膜有最佳化学亲和力的热塑性弹性体。
6.一种压力容器，包括沿一密封接头连接在一起的第一和第二外部塑料表层，该密封接头由模制在表层的外周边缘上的弹性体材料小珠形成，并形成密封接头线。
7.根据权利要求6所述的压力容器，还包括：进口导管，该进口导管模制在第一或第二表层上，以便使增压空气能够进入容器内部，从而使该容器膨胀。
CNA018194427A 2000-11-25 2001-11-20 连接塑料薄片材料的方法 Pending CN1476375A (zh)

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CN113799320A (zh) * 2018-11-16 2021-12-17 斯塔公司 由内而外制造具有防漏密封件的容器的方法

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CN101927566A (zh) * 2009-06-17 2010-12-29 泰科保健集团有限合伙公司 射频焊接设备
CN113799320A (zh) * 2018-11-16 2021-12-17 斯塔公司 由内而外制造具有防漏密封件的容器的方法
CN113799320B (zh) * 2018-11-16 2023-08-08 斯塔公司 由内而外制造具有防漏密封件的容器的方法

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